Stuffed sealed envelopes



April 23, 1968 H. A. sUTPHEN, JR 3,379,363

sTuFFEn SEALED ENvELoPEs Filed May 20, 1965 5 Sheets-Sheet 2 FIG-9 u E5l I I l I I j l D April 23, 1968 H. A. SUTPHEN, JR

STUFFED SEALED ENVELOPES 5 Sheets-Sheet 3 Filed May 20, 1965 UnitedStates Patent Ol 3,379,363 STUFFED SEALED ENVELGPES Harold A. Sutphen,Jr., Longmeadow, Mass., assigner to United States Envelope Company,Springfield, Mass., a corporation of Maine Filed May 20, 1966, Ser. N551,573 3 Claims. (Cl. 229-85) This invention relates generally tostuffed, sealed envelopes, and more specifically, this invention relatesto stuffed, sealed envelopes having a unique opening feature for readilyexposing the contents, and a method for eiiiciently manufacturing suchenvelopes from continuous webs of paper or similar iiexible material.

The term stuffed envelope is commonly used in the art when referring toan envelope into which its intended contents have been inserted, Thecontents, however, are usually inserted, either mechanically ormanually, after the envelope has been completely folded and sealedexcept for the closing or sealing iiap, which customarily remains freeuntil after the inserting operation is performed.

It is an object of the present invention to provide a stuffed, sealedenvelope, or an envelope-insert combination, in which the envelopeportion and insert portion are interrelated in structure so as tofunction as a unit in a unique manner, whereby a single, simpleapplication of opposed lateral forces acting at opposite ends will openthe envelope and expose its contents simultaneously.

It is another object of this invention to provide a method ofefficiently manufacturing such stuffed, sealed envelopes, orenvelope-insert combinations, from two ycontinuously moving webs ofexible material. Furthermore, if it is desired, more than two webs ofmaterial may be used to provide multiple insert portions.

Such stuffed, sealed envelopes are particularly useful in thedistribution of game coupons, advertising material, etc. at grocerystores, service stations, and many other places which distribute suchmaterial as an incentive for a customer who receives one of the stuffed,sealed envelopes to return to the distributor, and hopefully, bringadditional business to that distributor. For example, the stuffed,sealed envelopes, according to this invention, may conveniently be usedin the distribution of coupons on which there is printed a portion of asimulated check or bill. Envelopes containing portions of such simulatedchecks or bills are distributed by some stores and service stations topersons who visit their places of business. As soon as any visitorcollects enough portions to make up a complete check or bill, he becomeseligible to win a prize. Obviously, such coupons must be hidden fromView prior to the distribution thereof, and tightly sealed envelopeshave been found to be a very successful means for properly concealingthe coupons. It is also highly desirable in this particular envelope toincorporate therein some kind of a novelty opening device, such as thatprovided by the present invention, to aid in attracting attention ofcustomers, and thus derive the proper benefit from the advertisingfeature of the envelope and its contents.

Also, a particular advantage of the stuffed, sealed envelope accordingto this invention is the fact that it lends itself easily to theefficient and speedy manufacture of large quantities of such envelopesfrom two or more webs of paper. The webs may conveniently be preprintedwith the intended message, advertisement, or game material. The webs aresuperimposed in a manner such that they assume a particular relationshipto each other and are secured together at pre-determined locations,rendering the resultant product a unique envelope-insert combinationwhich functions in the intended manner described above.

With the above and other objects in View, as will 3,379,363 PatentedApr. 23, 1968 ICC hereinafter appear, the invention comprises thedevices, combinations, arrangements of parts hereinafter set forth andillustrated in the accompanying drawings of a preferred embodiment ofthe invention, from which the several features of the invention and theadvantages attained thereby will be readily understood by those skilledin the art.

In the drawings:

FIGURE 1 is a plan View of a sheet of insert material placed in positionover an envelope blank prior to its being enclosed in the envelopeblank, in accordance with this invention.

FIGURE 2 is a sectional View of the insert sheet and envelope blank,taken substantially along line 2 2 of FIGURE l.

FIGURE 3 is a sectional view of the insert sheet and envelope blank,taken substantially along line 3 3 of FIGURE 1.

FIGURE 4 is a plan View of a folded stuffed, sealed envelope inaccordance with this invention.

FIGURE 5 is a sectional View taken substantially along line 5 5 ofFIGURE 4.

FIGURE 6 is a sectional View taken along line 6 6 of FIGURE 4.

FIGURE 7 is a plan view illustrating the envelope after opening,exposing the message sheet.

FIGURE 8 is a plan View of an insert sheet and envelope blank,illustrating a ditferent embodiment of this invention.

FIGURE 9 is a plan view of a folded stuffed, sealed envelope accordingto this invention, made from the envelope-insert shown in FIGURE 8.

FIGURE l0 is an elevation View in schematic, illustrating how two websof tiexible sheet material may be combined as a first step in a methodof making the stuffed, sealed envelope illustrated in FIGURES 1-7inclusive.

FIGURE 11 is a plan view showing the successive stages of forming thestuffed sealed envelope in accordance with this invention.

Referring to the drawings, FIGURE 1 shows a sheet of insert material 20placed in face to face relation with a central section of the envelopeblank 22. As shown in this embodiment of the invention, the sheet ofinsert material 20, hereinafter referred to as insert for simplicity,and envelope blank 22 are coextensive at two opposite ends so that theyboth may be cut simultaneously, as a unit, from two superimposed webs ofpaper or similar iiexible material. It is not necessary in thisinvention, however, that the insert 20 and envelope blank 22 becoextensive at the opposite ends, as will be described in detailhereinafter, but this embodiment is easily adaptable to an etiicientmethod of manufacture.

Both the insert 26 and the envelope blank 22 are suitable for use inexisting printing processes and machinery. The envelope blank 22 may beprinted on the outside with advertising material if desired, and on theinside with a tinting or design to prevent the printing on the insertfrom showing through the envelope.

As best shown in FIGURES 1 and 3, the insert 20 and envelope blank 22are connected near their coextensive ends, preferably by adhesive areas24 and 26. Actually, this connection may be spaced inwardly from theedges more than that shown in the drawings if desired, as long as theinsert 20 and envelope blank 22 are free of each other between the lineof weakening 2S on the insert and the line of weakening 30 on theenvelope blank.

The lines of weakening 2S and 30 are preferably positioned near the endsof the insert 20 and envelope blank 22, so as to provide the largestpossible span between said lines of weakening, while still allowing roombetween each of the lines of weakening and the end of the envelope tograsp with the hands, as will be described in more detail hereinafter.The lines of weakening 28 and 3) may conveniently be lines ofperforations.

The envelope blank 22 is scored along lines 32, 34, 36, and 38, deningflaps 40, 42, 44, and 46 respectively, each being hingedly connected tothe central panel 48. Each of the said aps is foldable along its foldline, to enclose the insert 20. Preferably, the envelope blank asillustrated in FIGURE l is folded around insert by first folding Hap 46,then 42, which adhesively connects to flap 46 by means of adhesive strip43, and the smaller end aps 40 and 44 last, resulting in the stuffed,sealed envelope shown in FIGURES 4, 5, and 6. The aps 48 and 44 becomeadhesively connected to flaps 42 and 46 by means of adhesive strips 45and 47. It should be understood that various types of flap arrangementsmay be utilized in accordance with this invention, and the particularflap arrangement shown in the drawings is not intended to be restrictivein any sense of the word. For instance, the well-known triangular apstyle envelope may be utilized. Also, it is contemplated that theso-called seamless style envelope, ie., front and back walls adhereddirectly to each other without the use of intermediary end aps (such as40 and 44 in FIGURES 1-7 inclusive), may be utilized in accordance withthis invention.

As best shown in FIGURES 1 and 4, the insert 20 is slightly more narrowthan the space between score lines 34 and 38 to permit easy folding ofthe flaps 42 and 46 around the insert 20, into overlapping relationalong an adhesively connected seam 50 (FIGURE 5). The folded flaps 40,42, 44 and 46 form one main panel of the envelope, and theaforementioned main panel 48 forms the other. When the aps arecompletely sealed to each other, the contents of the envelope arecompletely hidden.

As mentioned previously, it may be desirable in certain situations touse multiple inserts with this envelope. The invention is not restrictedto the single insert shown in the drawings. When multiple inserts areused, the additional inserts would be superimposed over the singleinsert illustrated in FIGURE l, with the weakened line 28 of each insertsubstantially at the same position. Multiple inserts may be connectednear their ends, and also to the ends of the envelope blank 22. In theembodiment of the invention shown in FIGURES 1-7 inclusive, the inserts20, whether single or multiple, are firmly connected to opposite ends ofthe envelope by being incorporated into the end folds and by theadhesive areas 24, 26, 45, and 47. In all cases, however, the insert, orinserts 20 are completely free of the envelope blank 22 between theweakened line 28 of the insert or inserts 20 and the weakened line ofthe envelope blank 22.

Referring now particularly to FIGURES 4 and 7, application of opposedlateral forces to the opposite ends of the stuffed, sealed envelope 22in the indicated manner, will cause the envelope 22' to open, orseparate along the weakened line 30, which extends completely around thegirth of envelope 22. Simultaneously as envelope 22 separates alongweakened line 30, the insert 20, being firmly anchored at both ends ofenvelope 22', separates along its weakened line 28, leaving a stub 52 inthe larger portion of envelope 22'. Due to the relative positions of theweakened line 28 on the insert and weakened line 30 on the envelope 22',an appreciable message-carrying portion of insert 20 is exposed with theend stub of envelope 22. As shown in FIGURE 7, a single, simpleoperation is all that is required to break open the previouslycompletely sealed envelope 22', and to expose the major, usable portionof the insert 20. If desired, the insert 20 may be removed from the endstub of envelope 22 by tearing or cutting.

FIGURE 8 illustrates a modification of this invention in which theinsert 6) is not coeXtensive with opposite ends of the envelope blank22. ln this embodiment of my invention, the end of the coupon fallsshort of the edge of flap 44, and is secured `thereto by adhesive areas62 and 64. It should be understood, however, that the insert 60 couldjust as well be connected to panel 48, to the right of weakened line 30(as viewed in FIGURE 8) if desired, instead of being connected to flap44. Here again, the edges of the insert 60 lie inside fold lines 34 and38 of envelope blank 22 to permit each folding of the flaps 42 and 46.As shown in FIGURE 8, the other end of insert 60 is free of the envelopeblank 22. The only place of connection between insert 60 and envelopeblank 22 is to the right of weakened line 30, as viewed in FIGURE 8. Theleft end of the insert falls short of the score line 32 which willdefine the end of the stuffed, sealed envelope. It should also beunderstood that the ilaps will be folded and adhesively connected in thesame manner as described hereinbefore for the embodiment of theinvention shown in FIGURES l-7 inclusive.

FIGURE 9 illustrates the completely folded envelope 22 and the hiddeninsert 60 is shown in dotted lines. Weakened line 30 extends completelyaround the girth of the envelope 22. This envelope 22 may be opened,

or pulled apart, in the same manner as that described for the embodimentshown in FIGURES 1-7 inclusive Referring to FIGURE l0, a web 7tl offlexible sheet material, later to be cut into individual inserts forstuffed, sealed envelopes, is passed over guide roll 76 and through thepair of perforating rolls 74 and 76. Any convenient web perforatingmechanism well known in the art may be used to create a line ofperforations extending across substantially the entire width of the web.It is not necessary to this invention that the weakened line beperpendicular to the edges of the envelope 22 as shown in FIGURES l-7inclusive. The weakened line of the insert may be at an angle to theedges of the envelope 22', or alternately, several different angularconfigurations may be utilized if desired, resulting in the weakenedline across web 70 being other than in a perpendicular relation to theside edges of the web 70.

Patterns of adhesive are printed on predetermined areas of web 70 by theapplicator pads 78 and 80, carried by the roll 82, which pick upadhesive by peripheral contact with reservoir roll 84. Reservoir roll 84`rotates inside box 86 which contains adhesive material. Roll 82 rotatesin timed relation with the web 7 0 and perforating rolls 74 and 76, soas to apply the adhesive in patterns substantially as shown 'at 88 and90 in FIGURE 1l. Web 70 is then fed under roll 92 and into contact withweb 94, in timed relation with the movement of web 94, so that the twowebs are united and adhesively connected at 88 and 90as they passbetween rolls 92 and 96. t

The web 94 of envelope material is first fed through perforating rolls98 and 100 before being united with web 70. Perforating rolls 98` and100 rotate in timed relation with the perforating rolls 74 and 76 actingon web 70, such that the lines of perforations 28 on the insert materialweb 70, and the lines of perforations 30 on the envelope material web94, will assume a predetermined, spaced relation with each other, asbest shown in FIG- URE 11. It should also be understood that theweakened line 30 extending across the envelope 22 does not have to beperpendicular to the edges of the envelopes 22', but it may be in anangular position as hereinbefore described.

Webs 70 and 94 are combined in a manner such that the connectionstherebetween, i.e., the adhesive areas 88 and 90, lie on each side of animaginary line through which cuts will be made in the combined web toseparate adjacent envelopes. This can easily be seen by an examinationof the FIGURE 11 as a whole. Thus, when the webs 70 and 94 are combined,the adhesive areas 88 and 98, the lines of perforations 28, and thelines of perforations 30 assume a predetermined spacing and relationshipwith each other whereby the envelopes and inserts described in FIGURESl-7 inclusive may be formed.

After Combining webs 70 and 94, portions of web 94 at laterally oppositepositions are removed to dene the flaps 42 and 46 of adjacent envelopes.This is sometimes called notching in the art, and in this invention, thenotches 102 and 104 may actually cut slightly into the web 70 of insertmaterial. It should be understood that both the webs 70 and 94 at thispoint have been printed. These notches 102 and 104 may be formed by anyconvenient well-known means, such as llying cutters.

As viewed in FIGURE 11, the two webs 70 and 94 move from left to rightin unison. After notches 102 and 104 are cut, the tlaps 42 and 46 denedthereby are folded into overlying position with the web 70 andadhesively connected along a seam S0 by means of the adhesive strip 43,which is applied by well-known, conventional means. Adhesive strips 106and 108 are applied to the web 70 between the notches and will be usedto seal the end aps 40 and 44. Partially folded envelopes 22 are thensevered from the -united webs along an imaginary line between the areas106 and 108 of adhesive. Leading flap 44 is next folded and adhesivelyconnected by its adhesive 106 to the aps 42 and 46. Trailing aps 40 isthen folded and adhesively connected to flaps 42 and 46 by means of itsadhesive area 108. The stuffed, sealed enevelopes 22 are then gatheredfor packing.

Other and further modifications apart from those indicated herein couldbe made within the spirit of this invention.

I claim:

1. A stuffed, sealed envelope comprising, in combination, a sheet ofinsert material, an envelope enclosing said sheet, two opposite ends ofsaid sheet and envelope being substantially coextensive and said sheetand envelope being connected only near said coextensive ends, a Weakenedline extending around the girth of said envelope and spaced inwardlyfrom one end of said connected ends, a weakend line extending acrosssaid sheet at the opposite connected end but inward from saidconnection, whereby the end of said envelope and said sheet may bepulled apart as a unit exposing an appreciable area of said sheet.

2. An envelope according to claim 1 which includes multiple sheetsenclosed within said envelope.

3. An envelope according to claim 1 in which said sheet is divided intoa plurality of portions by weakened lines.

References Cited UNITED STATES PATENTS 702,100 1/1902 Keller 229-851,180,542 4/1916 Roden 229--85 3,061,174 10/1962 Zalkind 229-85 JOSEPHR. LECLAR, Primary Examiner. R. PESHOCK, Assistant Examiner.

1. A STUFFED, SEALED ENVELOPE COMPRISING, IN COMBINATION, A SHEET OFINSERT MATERIAL, AN ENVELOPE ENCLOSING SAID SHEET, TWO OPPOSITE ENDS OFSAID SHEET AND ENVELOPE BEING SUBSTANTIALLY COEXTENSIVE AND SAID SHEETAND ENVELOPE BEING CONNECTED ONLY NEAR SAID COEXTENSIVE ENDS, A WEAKENEDLINE EXTENDING AROUND THE GIRTH OF SAID ENVELOPE AND SPACED INWARDLYFROM ONE END OF SAID CONNECTED ENDS, A WEAKENED LINE EXTENDING ACROSSSAID SHEET AT THE OPPOSITE CONNECTED END BUT INWARD FROM SAIDCONNECTION, WHEREBY THE END OF SAID ENVELOPE AND SAID SHEET MAY BEPULLED APART AS A UNIT EXPOSING AN APPRECIABLE AREA OF SAID SHEET.